Drapery track system

ABSTRACT

A drapery track system is provided that includes one or more drapes, a motor configured to spin a shaft in both a clockwise direction and a counterclockwise direction, and a track system. The track system includes at least one track length secured to a fixed surface via a track securing mechanism, and a gearing assembly configured to interface with the motor to translate the clockwise spin direction and counterclockwise spin direction to first and second movements, respectively, of the drapes. The track length also includes a carrier channel and a guide wheel channel, and the gearing assembly includes a timing belt configured to be rotated by said motor. The track system further includes at least one track carrier configured to be attached to the timing belt such that the drapes can be moved by the track carrier. The track carrier includes a plurality of independently mounted track carrier wheel assemblies configured to rotate independently of each other within the carrier channel such that if one of the independently mounted wheel assemblies binds, the remaining independently mounted wheel assemblies can rotate freely. The track carrier further includes at least one guide wheel assembly located at a first end of the track carrier, the guide wheel assembly configured to freely rotate within the guide wheel channel of the track length. The system further includes a drape truck assembly configured to be removably secured to the drapes, and which includes at least two independently rotating truck wheels configured to freely rotate within the carrier channel of the track length such that the one or more drapes can be moved by the motor.

BACKGROUND OF THE INVENTION

1. Technical Field

Aspects of the embodiments relate to an integrated drapery and drapery track system that includes drapery controls, drapery tracks, and drapery adjustment devices for use in home or commercial applications.

2. Background Art

As can be appreciated by those of skill in the art, drapery systems for use in residential and commercial settings have made significant improvements in recent years. A drapery system will typically consist of a track, track carriers (for holding the drapes to the track), and some mechanism for moving the drapes back and forth along the track. The track is mounted either to a wall, or ceiling, and the mechanism for moving the drapes can be as simple as a pull cord-pulley system. Many people are probably familiar with the pull cord-pulley system, in which a person can pull the cord in one direction to move the drapes one way, and pull the cord in a different direction to reverse the movement of the drapes.

Other more sophisticated drapery systems are also available. For example, there can be a motor drive system to move the drapes back and forth. The motor can be manually controlled by one or more interfaces, which can consist of one or more switches to control the movement of the drapes, and/or the motor can be remotely controlled. Further, the motor can be programmable and controlled by a home personal computer (PC), or larger network in a business or “high-end” (i.e., very expensive) residential application.

When installing a drapery system, drapery tracks are sometimes installed flush against a ceiling. It is possible that either or both of the ceiling and floor will not be perfectly level, and this will become evident once the drapery fabric panels are hung from the track. That is, once the drapes are hung, an ordinary observation of the drapery system, in some circumstances, will easily show that the distance between the top of the drapery panel and the ceiling, or the bottom of the drapery panel and the floor will not be equal across the entire length of the track. There are two common solutions, neither of which may be desirable. The first solution would be to shim the track. This would require taking the entire track down and creating shims, which is not only time consuming, and thus adds to the expense of the installation, but also leads to the possibility of damaging the drapery system and/or ceiling/wall. The other solution would be to adjust the hooking on the drapery panels themselves, changing the distance between the top of the drape and the ceiling (or floor) by adjusting the length of the hook that hangs the drape to the trucks of the track (e.g., by cutting and/or twisting/bending the hooks). If the person who made the fabric panels is not present, another individual may not want to do this for fear of damaging the expensive drape material, and it can be just as difficult and expensive to accomplish as shimming the tracks. As those of skill in the art can appreciate, neither solution is easy to implement, and therefore are not very desirable to do.

In addition to the problems of securing the drapery track to a non-level ceiling, or over a non-level floor, the simple act of attaching the drapery track to the ceiling (or wall) can be difficult in and of itself. As those of skill in the art can appreciate, modern, sophisticated drapery systems include many moving parts, and a secure, non-interfering manner of installation of and between the components of the drapery system is paramount. Conventional solutions have tried to create special features in the top of the extrusion track that isolate the method of attachment from the parts that move. While this has met with some limited success in avoiding binding or catching of different moving components, installation can be difficult, and requires additional parts, which increases the expense thereof.

In addition to the problems of securing the track to the ceiling to avoid binding and catching of different moving components, there are problems associated with track installation in some circumstances in regard to alignment between track components. For example, extra-long or curved drapery tracks require the joining of several or many smaller length pieces. In one rendition, a bracket can be used to secure or splice both tracks next to each other. Because of tolerances in the bracket and track, there can be a significant amount of misalignment. This misalignment manifests itself in noise and/or binding of moving components that either or both the homeowner or commercial user will hear when the tracker carrier or truck pass through the splice. Even if movement is not inhibited or prevented, the noise as the track carrier and trucks pass over the splice, which in an automated system could be several times a day, can be annoying.

As discussed above, many currently available sophisticated drapery systems have attempted to make improvements in different areas of the drapery system to improve operation and reduce installation and use costs. One such attempt is the use of striations on the timing belt channel that guides the timing belt. Timing belts are used to move the track movable components, such as the track carriers and trucks. The striations that have been implemented allegedly reduce friction between the timing belt and an extrusion wall that makes up the timing belt channel. However, it has been found that triangular striations have sharp edges that can cause premature wear on the timing belt. This leads to premature failures of the timing belts, which causes a significant amount of frustration and some expense to the homeowners and commercial users of such sophisticated drapery systems.

One of the most sophisticated components of a drapery system is the track carrier. The track carrier—and generally there are at least one for each drape in the drapery system—is responsible for moving the drape back and forth, whether it is being moved by a motor and timing belt, or cord and pulley system. The track carrier is used to link the drape to the timing belt, which transfers motion from the motor (or cord and pulley system). As those of skill in the art can appreciate, drapes can be relative heavy, and it has been found that reducing friction and binding between the track carrier and the track is important. Thus, wheels have been used in an attempt to minimize friction, noise, and binding as the track carrier moves through a track. However, existing solid, hard plastic wheels have not proven to be effective in reducing noise to acceptable levels to ensure quiet operation, nor have they significantly minimized binding problems.

Certain companies have attempted to alleviate one or more of the problems discussed above. For example, U.S. Pat. No. 8,210,369, assigned to Lutron, describes a drapery system that includes an elongated track having two track portions and an elongated rectangular splice structure for coupling the two track portions together. Each track portion has a splice channel and at least one track hole located in the splice channel. The splice structure has at least two splice holes extending through the splice structure and is adapted to be received within the splice channels. Screws are received through the splice holes and extend into the track holes in a direction perpendicular to the splice structure. The distance between the two splice holes is less than the distance between the two track holes when the two track portions are aligned adjacent each other and the screws are not installed. Each of the screws contacts an edge of the respective track hole to provide a longitudinal force on the respective track portion when the screws are installed in the splice holes and track holes, such that the track portions are allegedly forced together.

A further example is U.S. Pat. No. 6,994,145, assigned to Lutron Electronics, in which is described an allegedly quiet drapery pull system that includes an elongated track that receives a master car and auxiliary cars. The track defines a pair of curved surfaces for nested receipt of roller members of the cars to facilitate linear tracking of the cars. The cars preferably include tires that are made from a resilient material to limit noises caused by rolling contact and by slipping and dragging of the tires upon contact with surface imperfections of the track. The drapery pull system preferably includes a drive belt connected to a reversible motor and to the master car for driving the master car in each of opposite directions. The drive belt is preferably made from a resilient material to limit noise associated with contact between the drive belt and drive pulley and between the belt and the track.

A further example is U.S. Pat. No. 6,935,403, assigned to Lutron Electronics, in which is described an allegedly quiet drapery pull system that includes an elongated track that receives a master car and auxiliary cars. The track defines a pair of curved surfaces for nested receipt of roller members of the cars to facilitate linear tracking of the cars. The cars preferably include tires that are made from a resilient material to limit noises caused by rolling contact and by slipping and dragging of the tires upon contact with surface imperfections of the track. The drapery pull system preferably includes a drive belt connected to a reversible motor and to the master car for driving the master car in each of opposite directions. The drive belt is preferably made from a resilient material to limit noise associated with contact between the drive belt and drive pulley and between the belt and the track. However, none of these prior art solutions have solved the problems of excess noise or binding of drapery systems.

Thus, there is a need for an integrated drapery and drapery track system that includes drapery controls, drapery tracks, and drapery adjustment devices for use in home or commercial applications.

SUMMARY OF THE INVENTION

It is to be understood that both the general and detailed descriptions that follow are explanatory only and are not restrictive of the embodiments.

DISCLOSURE OF INVENTION

According to an aspect of the embodiment, a drapery track system is provided that includes one or more drapes, a motor configured to spin a shaft in both a clockwise direction and a counterclockwise direction, and a track system. The track system includes at least one track length secured to a fixed surface via a track securing mechanism, and a gearing assembly configured to interface with the motor to translate the clockwise spin direction and counterclockwise spin direction to first and second movements, respectively, of the drapes. The track length also includes a carrier channel and a guide wheel channel, and the gearing assembly includes a timing belt configured to be rotated by said motor. The track system further includes at least one track carrier configured to be attached to the timing belt such that the drapes can be moved by the track carrier. The track carrier includes a plurality of independently mounted track carrier wheel assemblies configured to rotate independently of each other within the carrier channel such that if one of the independently mounted wheel assemblies binds, the remaining independently mounted wheel assemblies can rotate freely. The track carrier further includes at least one guide wheel assembly located at a first end of the track carrier, the guide wheel assembly configured to freely rotate within the guide wheel channel of the track length. The system further includes a drape truck assembly configured to be removably secured to the drapes, and which includes at least two independently rotating truck wheels configured to freely rotate within the carrier channel of the track length such that the one or more drapes can be moved by the motor.

According to a first aspect of the embodiments, a drapery track system is provided, comprising one or more drapes, a motor configured to be operable to spin a shaft in both a clockwise direction and a counterclockwise direction, wherein said clockwise spin direction of said shaft creates a first movement of said one or more drapes in a first direction, and wherein said counterclockwise spin direction of said shaft creates a second movement of said one or more drapes in a second direction opposite to said first direction, a track system that includes at least one track length secured to a fixed surface via a track securing mechanism, and a gearing assembly configured to interface with said motor and to translate said clockwise spin direction and counterclockwise spin direction to said first and second movements, respectively, of said one or more drapes, and wherein said at least one track length includes a carrier channel and a guide wheel channel, and wherein said gearing assembly includes a timing belt configured to be rotated by said motor, and wherein said track system further includes at least one track carrier configured to be attached to said timing belt such that said one or more drapes can be moved by said at least one track carrier that is moved by said timing belt that is moved by said motor, and wherein said track carrier includes a plurality of independently mounted track carrier wheel assemblies configured to rotate independently of each other within said carrier channel such that if one of said plurality of independently mounted wheel assemblies binds the remaining independently mounted wheel assemblies can freely rotate, and wherein said track carrier further includes at least one guide wheel assembly located at a first end of said track carrier, said guide wheel assembly configured to freely rotate within said guide wheel channel of said at least one track length, and a drape truck assembly configured to be removably secured to said one or more drapes, and wherein said drape truck assembly includes at least two independently rotating truck wheels configured to freely rotate within said carrier channel of said track length such that said one or more drapes can be moved by said motor.

According to the first aspect of the embodiments, the track carrier further comprises a second guide wheel, located at a second end of said track carrier opposite that of said first end, wherein said second guide wheel is configured to freely rotate within said guide wheel channel of said at least one track length and to operate with said first guide wheel to substantially prevent rotation and binding of said track carrier within said carrier channel of said at least one track length.

According to the first aspect of the embodiments, said guide wheel assembly comprises a guide wheel rim configured to rotate about a first axis perpendicular to a direction of travel of said track carrier, and a first outer tire portion (1606) located over said guide wheel rim, said first outer tire portion made of a substantially softer, higher frictional material than a material that said guide wheel rim is made of, such that said guide wheel assembly is configured to rotate substantially freely about the first axis, but is frictionally resistant to movement in any direction other than the direction of rotation. According to the first aspect of the embodiments, the substantially softer, higher frictional material comprises urethane.

According to the first aspect of the embodiments, each of said plurality of independently mounted track carrier wheel assemblies comprises a track wheel rim that is independently rotatable of said other truck wheel rims attached to a track carrier body portion of said track carrier, and wherein said track wheel rim is configured to rotate about a second axis perpendicular to a direction of travel of said track carrier, and a track wheel tire located over said track wheel rim, said track wheel tire made of a substantially softer, higher frictional material than a material that said track wheel rim is made of, such that each of said independent mounted truck carrier wheel assemblies are configured to rotate substantially freely about said second axis, but is frictionally resistant to movement in any direction other than the direction of rotation.

According to the first aspect of the embodiments, the substantially softer, higher frictional material comprises urethane, and each of said plurality of independently mounted track carrier wheel assemblies comprises a track wheel that is independently rotatable of other track wheels attached to a track carrier body portion of said track carrier, and wherein each of said track wheels are configured to rotate about an axis perpendicular to a direction of travel of said track carrier.

According to the first aspect of the embodiments, the carrier channel comprises a plurality of track carrier wheel guides located at a bottom of said carrier channel, and wherein each of said plurality of track carrier wheel guides are configured to retain a respective one of said plurality of track carrier wheel assemblies when rotating, such that lateral movement of said track carrier is substantially prevented.

According to the first aspect of the embodiments, said track securing mechanism comprises a substantially centrally located track retention channel, located on an upper interior surface of said track length, wherein said substantially centrally located track retention channel runs a length of said track length, a reinforced area of track length material located about said substantially centrally located track retention channel configured to strengthen said track length in a location of said substantially centrally located track retention channel, a first plurality of track mounting holes located along a scribe line that is substantially centrally located within said substantially centrally located track retention channel, and a second plurality of track securing apparatuses each of which is configured to be placed within a respective one of said first plurality of track mounting holes and secured to said fixed surface.

According to the first aspect of the embodiments, the drapery track system further comprises at least one other track length, wherein each track length includes two or more dowel pin holes correspondingly located on both ends of said track length such that a first dowel pin hole of a first track length at a first end of said first track length is in substantial alignment with a second dowel pin hole located on a second track length at a second end of said second track length, and a plurality of dowel pins, each of said plurality of dowels including one or more fins, configured to be inserted into first into either of first or second dowel pin hole of a first track length, and then to be inserted into either of corresponding said second or first dowel pin holes of a second track length, thereby joining two or more track lengths together in substantial alignment.

According to the first aspect of the embodiments the dowel pins further comprise a plurality of fins, located on both ends of said dowel pin, and the drapery track system further comprises a timing belt configured to be moved by said motor to move said drapes, and wherein said track length further includes a first and second timing belt channel, wherein each of said timing belt channels are formed by a timing belt channel inner wall and a timing belt channel outer wall, and wherein, each of said timing belt channel outer walls has an exterior surface that forms an outer layer surface of said track lengths, and an inner surface, and wherein each of said inner surface of said timing belt channel outer walls includes a plurality of substantially rounded striations of a first predetermined radius, said striations configured to provide a substantially frictionless surface with respect to said timing belt.

Still further according to the first aspect of the embodiments, said drape truck assembly further comprises a truck wheel carriage configured to mate with said least two independently rotating truck wheels, a truck height adjustment piece received by a bottom, lowest hanging portion of said truck wheel carriage, and configured to removably secure said one or more drapes to said truck wheel carriage, and further wherein said truck height adjustment piece is configured to be adjustable in height with respect said bottom, lower hanging portion of said truck wheel carriage, such that a height of said one or more drapes with respect to one or more horizontal surfaces can be adjusted.

According to the first aspect of the embodiments, said truck height adjustment piece comprises a bolt with a threaded portion configured to be received in a bolt-receiving threaded portion located on said bottom, lower hanging portion of said truck wheel carriage, such that upon turning said bolt in a clockwise or counter-clockwise direction, said drape can be raised or lowered, or visa-versa. According to the first aspect of the embodiments, each of said at least two independently rotating truck wheels comprises a truck rim portion that is independently rotatable of said other truck rim portions attached to said truck wheel carriage, and wherein said truck rim portion is configured to rotate about a third axis perpendicular to a direction of travel of said truck assembly, and a truck tire portion located over said truck rim portion, said truck tire portion made of a substantially softer, higher frictional material than a material that said truck rim portion is made of, such that each of said independently rotatable truck wheels are configured to rotate substantially freely about said third axis, but are frictionally resistant to movement in any direction other than the direction of rotation. According to the first aspect of the embodiments, said substantially softer, higher frictional material comprises urethane.

According to a second aspect of the embodiments, a track carrier for use in a drapery track system is provided comprising a first and second track carrier body part, configured to be joined together to form said track carrier, wherein each of said first and second track carrier body parts include first and second guide wheel mounting portions respectively, and further wherein said first and second guide wheel mounting portions form elongated portions extending away from each other and a middle portion formed by said joining of said first second track carrier body parts, a plurality of track carrier wheel assemblies each of which are configured to rotate about respective axes of rotation that comprise a first set of axes of rotation, and wherein each axis of rotation of said first set of axes of rotation are substantially perpendicular to first and second directions of travel of said tracker carrier, a plurality of guide wheel assemblies each of which are configured to rotate about respective axes of rotation that comprise a second set of axes of rotation, and wherein each axis of rotation of said second set of axes of rotation are substantially perpendicular to each axis of rotation of said first set of axes of rotation, and further wherein each axis of rotation of said second set of axes of rotation are substantially perpendicular to said first and second directions of travel of said track carrier, and a joining plate configured to be placed between said first and second track carrier body parts and to facilitate joining of said first and second track carrier body parts together.

According to the second aspect of the embodiments, the track carrier further comprises a plurality of timing belt clip attachment receptacles, and wherein said drapery track system includes one or more tracks, wherein each of said tracks includes a carrier channel configured to receive said plurality of track carrier wheel assemblies of said track carrier, and a timing belt configured to move said track carrier in both said first and second directions, said timing belt including a plurality of timing belt clips configured to releasably attach to said respective ones of said plurality of timing belt clip attachment receptacles, and further wherein each of said tracks further includes a guide wheel channel configured to receive said plurality of guide wheels of said track carrier, and wherein each of said plurality of track carrier wheel assemblies are configured to rotate within said carrier channels of said one or more tracks and wherein each of said plurality of track carrier guide wheel assemblies are configured to rotate within said guide wheel channels of said one or more tracks.

According to the second aspect of the embodiments, said track carrier wheel assembly comprises a track wheel rim made of a first material and which is independently rotatable of other truck wheel rims attached to a track carrier body portion of said track carrier, and wherein each said track wheel rim is configured to rotate about an axis perpendicular to a direction of travel of said track carrier, and a track wheel tire made of a second material, and which is configured to be located over said track wheel rim such that said track wheel tire contacts portions of said carrier channel while each of said plurality of track wheel assemblies rotates.

According to the second aspect of the embodiments, said second material is softer than said first material and exhibits greater frictional contact with said carrier channel in any direction not in said first and second directions of travel when rotating, and further wherein said second material comprises urethane. According to the second aspect of the embodiments, said track carrier wheel assembly comprises a track wheel that is independently rotatable of other track wheels attached to a track carrier body portion of said track carrier, and wherein each of said track wheels are configured to rotate about an axis perpendicular to a direction of travel of said track carrier.

According to the second aspect of the embodiments, each of said a plurality of guide wheel assemblies comprises a guide wheel rim made of a third material, and a guide wheel tire made of a fourth material, and which is configured to be located over said guide wheel rim such that said guide wheel tire contacts said guide wheel channels while each of said plurality of guide wheel assemblies rotates, and wherein the fourth material comprises urethane.

According to the second aspect of the embodiments, said plurality of guide wheel assemblies comprise a first guide wheel assembly located at a first end of a first guide wheel portion of said track carrier, and a second guide wheel assembly located at a first end of a second guide wheel portion of said track carrier opposite to that of said first end guide wheel portion, wherein in operation within said guide wheel channel, said pair of guide wheel assemblies are configured to substantially prevent rotation of said track carrier about any axis substantially perpendicular to said line formed by said first and second directions of travel.

According to the second aspect of the embodiments each of said plurality track wheel carrier assemblies is configured to rotate independently of each other, and each of said plurality guide wheel assemblies is configured to rotate independently of each other. Still further according to the second aspect of the embodiments, each of said axes of said first set of axes of rotation reside within a first plane, and wherein each of said axes of said second set of axes of rotation reside within a second plane, and further wherein said first plane and said second plane are perpendicular to each other and to a third plane that encompasses said first and second directions of travel.

According to a third aspect of the embodiments, a track for use in a drapery track system is provided comprising a pair of timing belt channels configured to contain a timing belt therein, each of said pair of timing belt channels formed by a timing belt channel inner wall and a timing belt channel outer wall, wherein said timing belt channels are substantially parallel to each other, and wherein said timing belt outer walls form an outer portion of said track, a carrier channel located between said timing belt inner walls, formed in part by said timing belt channel inner walls, a substantially planar bottom for both of said pair of timing belt channels, and wherein an opening is formed in said substantially planar bottom wall in said carrier channel to form a guide wheel channel, a track mounting mechanism configured to secure said track to a fixed surface, and a plurality of substantially rounded striations located on each of said inner wall portions of both of said timing belt channel outer walls, wherein said striations have a first predetermined radius, and said striations are configured to provide a substantially frictionless surface with respect to said timing belt.

According to the third aspect of the embodiments, the track further comprises at least four dowel pin holes, two of which are located at a first end of said track, and two of which are located at a second end of said track, such that when a second end of a second track is located adjacent to said first end of a first track, the four dowel pin holes are in substantial alignment with each other, and a plurality of dowel pins, each of said plurality of dowels including one or more fins, wherein said dowel pins with fins can be inserted into any of said dowel pin holes on said first track or said second track, and mate with corresponding dowel pin holes on said second track or said first track, thereby joining two or more track lengths in substantial alignment.

According to the third aspect of the embodiments, said dowel pins further comprise the one or more fins on said dowel pins located at a first end of said dowel pin, and further wherein said dowel pins further comprise a plurality of fins located on both sides of said dowel pin. According to the third aspect of the embodiments, said track mounting mechanism further comprises a substantially centrally located track retention channel, located on an upper interior surface of said track, wherein said substantially centrally located track retention channel runs a length of said track, a reinforced area of track material located about said substantially centrally located track retention channel configured to strengthen said track in a location of said substantially centrally located track retention channel, a scribe line located substantially centrally within said track retention channel, a plurality of track mounting holes located along said scribe line, and a plurality of track securing apparatuses, a respective one of each to be placed within a respective one of said plurality of track mounting holes and secured to a fixed surface upon which said track is to be mounted.

The aspects of the embodiments described herein seek to overcome or at least ameliorate one or more of several problems described above, including but not limited to drapery track systems that bind, wear prematurely and/or are excessively noisy.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects and features of the embodiments will become apparent and more readily appreciated from the following description of the embodiments with reference to the following figures. Different aspects of the embodiments are illustrated in reference figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered to illustrative rather than limiting. The components in the drawings are not necessarily drawn to scale, emphasis instead being placed upon clearly illustrating the principles of the aspects of the embodiments. In the drawings, like reference numerals designate corresponding parts throughout the several views.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 illustrates a perspective view of a drapery system for use in either a residential or commercial setting according to an embodiment.

FIGS. 2A and 2B illustrate a bottom, partial view of a track and its components used in the drapery system of FIG. 1 according to an embodiment.

FIG. 3 illustrates a view of a plurality of drape truck assemblies holding a drape in the drapery system of FIG. 1 according to an embodiment.

FIG. 4 illustrates a detailed view of a drape truck assembly of FIG. 3 according to an embodiment.

FIG. 5 illustrates a cut-away, end view of the track of FIG. 2A showing a track securing configuration and track securing apparatus according to an embodiment.

FIG. 6 illustrates the cut-away view of the track of FIG. 5 including a portion of a drape truck assembly showing a clearance formed by the track securing configuration and track securing apparatus between an upper portion of an interior portion of the track with regard to the upper portion of a pair of wheels of the drape truck assembly according to an embodiment.

FIG. 7 illustrates a perspective view of the track of FIG. 2A showing a plurality of dowel pin holes configured to accept dowel pins with fins for securing a first track to a second track according to an embodiment.

FIG. 8 illustrates a perspective view of a dowel pin with fins for use with the dowel pin holes to facilitate alignment and interconnection of a first track with a second track according to an embodiment.

FIG. 9 illustrates a perspective view of the track of FIG. 2A with a plurality of dowel pins with fins inserted into respective ones of a plurality of dowel pin holes according to an embodiment.

FIG. 10 illustrates first and second tracks just prior to mating using one or more dowel pins with fins and dowel pin holes according to an embodiment.

FIG. 11A illustrates cut-away, end view of the track of FIG. 2A showing a plurality of striations in each timing belt channel of the track according to an embodiment.

FIG. 11B illustrates a close-up view of the striations of the portion of the track shown in FIG. 11A according to an embodiment.

FIG. 12 illustrates a plurality of track carriers for use in the drapery system of FIG. 1 according to an embodiment.

FIG. 13 illustrates the plurality of track carriers as shown in FIG. 12, one of which is assembled with the timing belt of FIGS. 2A and 2B, and the other which is in a partially disassembled state, according to an embodiment.

FIGS. 14A-14C illustrate several views of one of the track carrier shown in FIG. 12 according to an embodiment.

FIG. 15 illustrate a cut-away, end view of the track of FIG. 2A with a simplified view of the track carrier of FIGS. 12-14 according to an embodiment.

FIGS. 16A and 16B illustrate a simplified side and top view of the track carrier of FIGS. 12-14 with a guide wheel assembly according to an alternate embodiment.

FIG. 17 illustrates the track carrier of FIGS. 12-16B when tilted causing a potential binding situation, but which is alleviated by the independently rotatable wheel assemblies of the track carrier according to an embodiment.

LIST OF REFERENCE NUMBERS FOR THE MAJOR ELEMENTS IN THE DRAWINGS

The following is a list of the major elements in the drawings in numerical order.

-   100 Drapery System -   102 Motor -   104 Track -   106 Drape -   108 Drape Truck Assembly (Truck Assembly) -   110 Drape Hook -   112 Track Carrier -   202 Timing Belt -   204 Timing Belt Gear -   206 Timing Belt Gear Teeth -   208 Timing Belt Teeth -   210 Track Timing Belt Channel Inner Wall -   212 Track Timing Belt Channel Outer Wall -   214 Track Retention Channel -   216 Track Mounting Hole -   218 Scribe Line -   220 Motor Drive Arm Receptacle -   222 Timing Belt Channel -   402 Truck Wheel Carriage -   404 Truck Height Adjustment Piece -   406 Truck Rim -   408 Truck Tire -   410 Truck Wheel -   502 Track Securing Apparatus -   504 Track Securing Mechanism -   506 Reinforced Area -   508 Carrier Channel -   510 Guide Wheel Channel -   602 Clearance -   702 Dowel Pin Hole -   704 Dowel Pin Hole Extrusion Channel (Extrusion Channel) -   800 Dowel Pin with Fins -   802 Fin -   1102 Striation -   1202 Track Carrier Wheel Assembly -   1203 Track Wheel Rim -   1204 Track Wheel Urethane Tire -   1205 Track Wheel -   1206 Truck Carrier Body -   1207 Guide Wheel Mounting Portion -   1208 Guide Wheel -   1210 Joining Plate -   1211 Timing Belt Clip Attachment Receptacle -   1212 Timing Belt Clip -   1502 Track Carrier Wheel Guide -   1600 Guide Wheel Assembly -   1601 Guide Wheel Rim -   1602 Guide Wheel Urethane Tire (Guide Wheel Tire)

DETAILED DESCRIPTION OF THE INVENTION

The embodiments are described more fully hereinafter with reference to the accompanying drawings, in which different aspects of the embodiments are shown. In the drawings, the size and relative sizes of layers and regions may be exaggerated for clarity. Like numbers refer to like elements throughout. The embodiments may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the inventive concept to those skilled in the art. The scope of the embodiments is therefore defined by the appended claims. The detailed description that follows is written from the point of view of a control systems company, so it is to be understood that generally the concepts discussed herein are applicable to various subsystems and not limited to only a particular controlled device or class of devices, such as a drapery controlled system.

Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the embodiments. Thus, the appearance of the phrases “in one embodiment” on “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular feature, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

FIG. 1 illustrates a perspective view of drapery system 100 for use in either a residential or commercial setting, and FIGS. 2A and 2B illustrate a bottom, partial view of track 104 and its components used in drapery system 100 of FIG. 1 according to an embodiment. Drapery system 100 includes track 104, motor 102, timing belt 202, drapes 106 a,b, drape truck assembly (truck assembly) 108, hooks 110, and track carriers 112 a,b. Track 104 can be made up of one, two or even several different track pieces joined together. According to a further aspect of the embodiments, truck assembly 108 is described in greater detail below in regard to FIGS. 3 and 4. According to an aspect of the embodiments, an apparatus and method for securing tracks 104 to a ceiling is described in greater detail below in regard to FIGS. 5 and 6. According to an aspect of the embodiments, an apparatus and method of joining track portions together is described in greater detail below in regard to FIGS. 7-9. According to a further aspect of the embodiments, striations on a timing belt channel guide are described in greater detail below in regard to FIG. 10. According to still a further aspect of the embodiments, track carrier 112 is described in greater detail below in regard to FIGS. 11-16. Each aspect of the embodiments will now be discussed in turn.

As briefly mentioned above, FIGS. 2A and 2B illustrate a bottom, partial view of track 104 and several of its components used in drapery system 100 of FIG. 1 according to an embodiment. Shown in FIG. 2A is timing belt 202. Timing belt 202, which is shown in greater detail in FIG. 2B, include timing belt (TB) teeth 208, and timing belt gear (TBG) 204, and TBG teeth 206. Timing belt 202 travels around timing belt gears 204 a,b, when driven, in this instance, by motor 102 (shown in FIG. 1, but not in either of FIG. 2A or 2B) by action of a motor drive arm that fits into motor drive arm receptacle 220 a (or 220 b, in the event motor 102 should be placed at the opposite end of tracks 104). Timing belt 202 travels in timing belt channel 222, which is partially comprised of track timing belt outer wall 212 and track timing belt inner wall 210. Timing belt channel 222 is shown in several of the Figures, but especially FIG. 11 with regard to striations 1102 (described in greater detail below).

Further shown in FIG. 2A are track mounting holes 216, which are placed at predetermined intervals along an upper surface of track 104, and which have been created along scribe line 218, all of which is also described in greater detail below. Track mounting holes 216 are located within track retention channel 214; this is shown in greater detail in regard to FIGS. 5 and 6.

Attention is now directed towards FIG. 3. FIG. 3 illustrates a view of drape 106 held up by drape hooks 110 and truck assemblies 108 to track 104, and FIG. 4 is a detailed view of truck assembly 108 according to an embodiment. Truck assembly 108 is one part of the interface between drapes 106, and track 104. Drape hooks 110 are connected to drapes 106, usually at the time of installation. Typically, drape hooks 110 are simple hook devices, designed to attach to pre-strengthened points on drapes 106 (not shown) and then to drape truck assembly 108. Drape truck assembly 108 is itself made up of two main components according to an embodiment: truck wheel carriage 402, and truck height adjustment piece 404. According to an embodiment, the combination of truck wheel carriage 402 and truck height adjustment piece 404 provides height adjustability. Simply by turning truck height adjustment piece 404 clockwise or counter clockwise, the installer can lower or raise a corresponding portion of drape 106. The installer now has the ability to adjust drapes 106 to ensure that they are parallel without having to modify the track installation, or the drape material itself. According to an embodiment, truck height adjustment piece 404 screws into truck wheel carriage 402 using a threaded portion of truck height adjustment piece 404 and corresponding threaded receptacle of truck wheel carriage 404. Truck height adjustment piece 404 can then be raised or lowered—and consequently drape 106 can be raised or lowered—by rotating truck height adjustment piece 404 clockwise or counter-clockwise.

According to embodiments, the amount of adjustability is determinable by the length of truck height adjustment piece 404 and the amount of threaded portion. According to further embodiments, ½″ of adjustability in either direction can be provided. As those of skill in the art can appreciate, such height adjustment example is just that, and is not meant to be taken in limiting sense. Other lengths, and thus adjustment heights, of truck height adjustment piece 404 can be provided and used. According to a further embodiment, other mechanisms can be provided and used to secure track 104 to the ceiling or wall in place of screw piece 404 and provide height adjustment functionality. For example, piece 404 can be a plain pin with a plurality of holes spaced apart, and a second pin can be used to secure it at a desired position to provide a desired height for drapes 104. The second pin, similar to a cotter pin, can be re-located to provide the appropriate height adjustment. Other height adjustment mechanisms can be envisioned as well, and all are considered to be within the scope of the embodiments.

Truck assembly 108 further includes at least first and second truck wheels 410 a,b. As those of skill in the art can appreciate, typically there are at least two truck wheels 410 on each truck assembly, but there can be three or more as well, depending on the size of track 104 and weight of drapes 106. Each of first and second truck wheels 410 a,b comprise truck tire 408, made of a first material, and truck rim 408, made of a second material; much like the wheel assemblies used in track carrier 112, discussed in greater detail below, the first material is generally a hard plastic material, and the second material is a softer, more frictional material. According to an embodiment, the second material can be a urethane, thought that is not the only material that incorporates the features as described above. According to further embodiments, other materials that can be used include neoprene, silicone, nitride (Buna-N), viton, among others, as those of skill in the art can appreciate.

As will be discussed in greater detail below, it is generally desired in operation of drapery track system 100 that the components that make up the system operate smoothly, with little or no noise, and vibration, and to further resist tendencies to bind, especially components that reside within track 104. Thus, according to an embodiment, truck assembly 108 includes components that have been designed to be substantially smooth in operation, i.e., rotate freely, operate as noiselessly as possible, and resist tendencies to bind. Therefore, in furtherance of the desired substantially smooth, noise free operation of truck assembly 108 according to an embodiment, truck wheels 410 a,b sit within track carrier wheel guides 1502 a,b (shown below in regard to FIG. 15), which substantially prevents any side-to-side (lateral) motion of truck assembly 108, due to the frictional engagement of the grooves of track carrier wheel guides 1502. As those of skill in the art can appreciate, side-to-side motion of truck assembly 108 will lead to situations in which binding can occur and/or excessive noise. That is, if truck assembly 108 were allowed to wander within carrier channel 508, then it could bind, and/or create excessive noise as it moved from side-to-side. According to a further embodiment, however, because truck assembly 108 includes wheels 1202 a,b with tires 1204, track 104 need not include track carrier wheel guides 1502; in this case, track 104 would look substantially similar to the configurations as shown in FIGS. 5, 6, 7, 9, and 11A. Therefore, according to further embodiments, track 104, as configured and depicted in FIGS. 5, 6, and 9 without track carrier wheel guides 1502, can be used with any one or more of the different assemblies described herein, as can the particular configuration of track 104 as shown in depicted in FIGS. 7, 11A, 15, and 17 that does includes track carrier wheel guides 1502.

In furtherance of the desired substantially noise-free and binding-free operation of truck assembly 108, truck wheel 410, which is made of truck rim 406 and urethane truck tire (truck tire) 408, provides substantially smooth noise-free operation through carrier channel 508. According to an embodiment, truck tire 408 can be made separately, fashioned in the shape of an “O-ring,” using known O-ring manufacturing techniques. O-rings can be produced by extrusion, injection molding, pressure molding, or transfer molding processes, as those of skill in the art can appreciate. In addition, truck tire 408 can also be made using an over-molding process. As those of skill in the art can appreciate, over-molding is the process wherein a pre-mold is insert molded out of a first material, and then transferred to a second mold. Using a single shot process, a second material is then molded over the first to create the final molded part.

According to an aspect of the embodiments, truck tire 408 can be made of urethane, which is softer than the polystyrene plastic that is typically used in the manufacture of many of the other components of drapery system 100, as those of skill in the art can appreciate. Truck tire 408 according to an embodiment provides not only a softer, cushioned interface between track carrier wheel guide 1502 of carrier channel 508 and truck assembly 108, but it also provides a greater frictional engagement with track carrier wheel guide 1502. However, as those of skill in the art can appreciate, the frictional engagement typically does not come into play when truck assembly 108 rotates, but does come into play if truck wheel 410 attempts to move in a side-to-side motion (this is shown and described in greater detail below in regard to FIG. 15, and track carrier 112; see, therefore, arrows A and B in FIG. 15). Thus, use of an O-ring as truck tire 408 over truck rim 406 substantially prevents side-to-side motion, which substantially eliminates binding and excessive noise according to an embodiment. Furthermore, it should be apparent to those of skill in that art that while a specific material has been discussed in regard to the aspect of the embodiments of truck tire 408, other materials can also be used that are different than urethane but which provide substantially similar functionality in terms of frictional engagement and cushioning affect. Thus, the aspects of the embodiments are not meant to be, nor should they be taken to be limited to urethane as the only material of which truck tire 408 can be made of.

In furtherance of the desired effect of non-binding of the components of drapery system 100, including those that operate within track 104, each of first and second truck wheels 410 a,b are rotatable independently of each other. That is, if, for example, first truck wheel 410 a binds, for whatever reason, second truck wheel 410 b need not bind as well and will continue to rotate freely about its axis of rotation. While having independently rotatable truck wheels 410 cannot prevent binding, should it occur, it lessens the impact by at least half by allowing the non-binded wheel to continue to rotate. An occurrence of binding of a wheel is shown in FIG. 17 in regard to track carrier 112, and track carrier wheel assemblies 1202 a,b; this is discussed in greater detail below in regard to track carrier 112, but the principle with respect to truck wheels 410 a,b is substantially similar.

Turning now to FIGS. 5 and 6, shown therein is a side, cut-away view of track 104 of FIG. 2 illustrating a track securing mechanism 504 and track securing apparatus 502 according to an embodiment. FIG. 6 illustrates the side, cut-away view of track 104 of FIG. 5 including a portion of truck assembly 108 showing a clearance 602 formed by track securing mechanism 504 and track securing apparatus 502 between an upper portion of an interior portion of track 104 with regard to the upper portion of a pair of wheels of truck assembly 108 according to an embodiment.

As shown in FIG. 5, track securing mechanism 504 comprises reinforced area 506, track retention channel 214, track securing apparatus 502, and scribe line 218. Reinforced area 506 is a portion of track channel 104 that includes additional material (typically, but not necessarily limited to aluminum) built up around track retention channel 214, which is recessed to provide clearance 602 between track securing apparatus 502 and the top of truck assembly 108 (as shown in FIG. 6). Scribe line 218 is provided to make it easier for installers to find the middle of track 104 to obtain the best possible securing configuration of track 104 to a ceiling.

Track retention channel 214 is designed into track 104 such that track securing apparatus 502, according to a non-limiting example, a #8 screw, can be recessed into track 104 above carrier channel 508 which is where track carrier 112 and drape truck assembly 108 move within track 104. Also shown as part of track 104 is guide wheel channel 510, which is discussed in greater detail below. According to an embodiment, track retention channel 214 is positioned in the center of track 104 and any protrusion from track securing apparatus 502 is well out of the way of any moving parts (such as track carrier 112, or truck assembly 108). Scribe line 218 is added to track 104 as shown to help installers drill accurate holes in the field when assembling drapery system 100. Even in the event that track carrier 112 and/or truck assembly 108 should jump up for some reason, it would not be able to interact or touch track securing apparatus 502 because of reinforced area 506; this substantially prevents interference between the different components and blockages. According to further embodiments, track securing apparatus 502 can also be nail, wood or metal screw, rivet, or other fastening mechanism. Other securing mechanisms can be envisioned as well, and all are considered to be within the scope of the embodiments.

As described above, drapery system 100 can include several, if not many sections of track 104 joined together in the case of a drapery system for a large room, such as a conference room, or large banquet hall, in a hotel for example. If two or more of the sections were misaligned, excess noise by track carriers 112 can be generated and/or binding can occur. To prevent this situation from occurring, system and method for aligning tracks 104 is presented in FIGS. 7-10. FIG. 7 illustrates a perspective view of track 104 of FIG. 1 showing a plurality of dowel pin holes 702 configured to accept dowel pins 800 with fins for securing first track 104 a to second track 104 b according to an embodiment, as well as dowel pin hole extrusion channel (extrusion channel) 704. Extrusion channel 704, also shown in FIG. 5, is provided to assist in manufacturing track 104, as it is typically manufactured using an extrusion process, which is well known to those of skill in the art. FIG. 8 illustrates a perspective view of dowel pin 800 with fins for use with dowel pin holes 702 a,b to facilitate alignment and interconnection of first track 104 a with second track 104 b according to an embodiment, and FIG. 9 illustrates a perspective view of track 104 with a plurality of dowel pins 800 a,b with fins inserted into respective ones of a plurality of dowel pin holes 702 a,b according to an embodiment. FIG. 10 illustrates first and second tracks 104 a,b just prior to mating using one or more dowel pins 800 with fins and dowel pin holes 702 according to an embodiment.

According to an embodiment, dowel pin holes 702 a,b are provided at each end of track 104. Dowel pin holes 702 are sized to accept dowel pins 800, with fins 802. According to a further embodiment, fins 802 are sized such that they provide a tight, securing fit between dowel pins 800 and track 104. As can be seen in FIG. 8, fins 802 generally cover about half the length of dowel pins 800, though that need not be the case. According to further embodiments, fins 802 can be provided on either end of dowel pins 800 with fins. According to an embodiment, the end of dowel pin 800 with no fins 802 is configured as a close slip fit with its respective down pin holes 702 to aid in substantially minimizing misalignment.

Attention is now directed towards FIG. 10, which illustrates tracks 104 a,b just prior to mating using dowel pins 800 with fins and dowel pin holes 702 according to an embodiment. According to an embodiment, dowel pins 800 can be installed either at the place of manufacture, or in the field. Once dowel pins 800 have been installed into track 104 a, track 104 b can be mated with track 104 a. Use of dowel pins 800 provides substantially better alignment between the two (or more) sections of track, and easier to obtain than prior art systems/methods. According to a further embodiment, dowel pins 800 can also be installed either before or after track 104 has been mated to the ceiling or wall. Improving alignment between sections of track 104 through the use of dowel pins 800 minimizes the possibility of noise resulting from misalignment.

FIG. 11A illustrates an end view of track 104 of FIG. 1 showing a plurality of striations 1102 in each timing belt channel 222 of track 104 according to an embodiment. Striations 1102 as shown in FIG. 11A are generally rounded according to an embodiment. Rounding striations 1102 provide at least two benefits according to an embodiment. First, rounded striations 1102 offer less frictional contact with timing belt 202. The rounded nature of rounded striations 1102 make it easier for timing belt 202 and timing belt clip 1212 to move across it; as those of skill in the art can now appreciate, the sharp, triangular striations of conventional tracks in conventional drapery systems dig into timing belt 202 and timing belt clip 1212, causing additional friction and wear on timing belt 202 and timing belt clip 1212, leading to premature breakage. In the case of timing belt clip 1212, significant scraping and scouring can occur. In addition, it is easier to manufacture track 104 with rounded striations 1102 than with triangular striations. As those of skill in the art can appreciate, one known process for making track 104 is an extrusion process. In this process, molten aluminum is pushed out through a die, and then pulled into a cooling bin. If the portion of the die includes triangular striations, the molten aluminum will experience increased frictional flow across that portion of the die. This causes the pulling action to be less consistent, as some parts of the extruded material will encounter much less friction than others. Consequently, by making the striations rounded, the friction that is developed is kept to a level more consistent with other flatter, or other rounded portions (such as in the corners of all of the channels), thereby making the entire extrusion process more consistent in terms of friction.

As shown in FIG. 11B, rounded striations 1102 can have radius of curvatures of r₁ and r₂. According to an embodiment, r₁ and r₂ can be the same, or they can be different, and according to further aspects of the embodiments, the radii of curvature can vary along the height of timing belt channel 222, meaning that there can be as many different radii of curvature as there can be striations 1102. According to an embodiment, striations 1002 are made with a radius of curvature of about 0.02 inches. According to a further embodiment, striations 1002 (with radii of curvature r₁ and r₂) are made with a radius of curvature that ranges from about 0.015 inches to about 0.025 inches. According to a further embodiment, each striation 1002 need not be as exaggerated as shown in FIG. 11B; that is, the striations 1002 can be less than a full half-circle, and often comprise an arc of about 45°; according to a further embodiment, the arc of striations 1002 can range from about 30° to about 60°. Further, the distance between radii on a given side (i.e., a peak-to-peak distance (distance between lines C and D, or distance D₁) can be about 0.063 inches, and according to a further embodiment can be between about 0.058 inches to about 0.068 inches. Further, the distance between radii on a given side (i.e., a valley-to-valley distance (distance between lines E and F, or distance D₂) can be about 0.063 inches, and according to a further embodiment can be between about 0.058 inches to about 0.068 inches. According to still a further embodiment, the distance from the lowest point (valley) to the highest (peak) of striations 1002, which is shown as distance D₃ (the distance between lines G and H), can be about 0.015 inches, and according to a further embodiment, can be between about 0.010 inches to about 0.020 inches. According to still a further embodiment, all of the dimensions shown and discussed above in regard to radius, heights, distances, and so on, in regard to FIG. 11B, or any of the other Figures discussed above or below, can be modified, changed, or altered according to the specific design and shape and size of track 104 at the time of manufacture, and the different aspects of the embodiments are not limited to the examples discussed above.

As discussed above, prior art solutions attempting to reduce noise in operation of drapery assemblies have first tried incorporating wheels, and then making them from resilient materials. These, though, have not met with success. Track carrier 112, according to various aspects of the embodiments, however, further includes features that overcome the problems of the prior art in reducing noise when operating motorized drapery systems (though embodiments described herein are not limited to motorized systems). FIG. 12 illustrates a plurality of track carriers 112 for use in the drapery system of FIG. 1 according to an embodiment, FIG. 13 illustrates the plurality of track carriers 112 as shown in FIG. 12 assembled with 202 timing belt of FIGS. 2A and 2B according to an embodiment, FIGS. 14A-C illustrate several views of one the track carriers 112 shown in FIG. 12 according to an embodiment, and FIG. 15 illustrate a cut-away, end view of track 104 of FIG. 2A with a simplified view of track carrier 112 of FIGS. 12-14 according to an embodiment.

Track carrier 112 includes one or more track carrier wheel assemblies 1202 (each of which comprise track wheel rim 1203 and track wheel urethane tire (tire) 1204), first and second track carrier bodies 1206 a,b, first and second guide wheels 1208 a,b, joining plate 1210, a plurality of timing belt clip attachment receptacles 1211 a-d, and first and second timing belt clips 1212 a,b. According to an embodiment, track wheel rim 1203 and tire 1204 can be fashioned as a unitary assembly, of the same material, such that there is no separate “tire.” In this case, the assembly of track wheel rim 1203 and tire 1204 can be referred to simply as track wheel 1205, as shown in FIG. 12. According to an embodiment, tire 1204 can be a standard “O” ring device, sized appropriately to fit over track wheel rim 1203, and can be made of any one of neoprene, silicone, nitrile (Buna-N), and viton, or another substantially similar material. According to still a further embodiment, track wheel rim 1203 and tire 1204 can be made according to an over-molding process as described above. In assembly, first and second track carrier bodies 1206 a,b are joined together with joining plate 1210 placed between them (see dashed lines in FIG. 13), through the use of screws, bolts, etc. Track carrier wheel assembly 1202, or track wheel 1205, can be press-fit, snap-fit onto first and second track carrier bodies 1206 a,b, or they can be screwed, bolted together, in a manner well known to those of skill in the art, as can first and second guide wheels 1208 a,b. From here on in, any discussion of track carrier wheel assembly 1202 includes use, as a further embodiment, of track wheel 1205. However, in fulfilment of the dual purposes of clarity and brevity, reference will only be made to track carrier wheel assembly 1202. Timing belt clips 1212, seen in FIG. 13, attach to track carrier 112 at any one of timing belt clip attachment receptacle 1211 a-d, typically by a press fit operation. According to an embodiment, each track carrier 112 includes timing belt clip attachment receptacle on both sides of track carrier 112, as seen in FIG. 12, so that timing belt 202 can be attached thereto on either side. A partially disassembled view of track carrier 112 is shown in FIG. 13 according to an embodiment.

As can be seen especially in FIG. 12, first and second guide wheels 1208 a,b are located at first and second guide wheel portions 1207 a,b, respectively, of track carrier 112, which are, according to an embodiment, located at opposite ends of track carrier 112 (as those of skill in the art can appreciate, other locations of the one or more guide wheels 1208 a,b with respect to track carrier 112 are also possible). Guide wheels 1208 provide a means for much quieter operation of track carrier 112 by prohibiting excess shimmy in operation of track carrier 112 as it moves within track 104. FIG. 15 illustrates the principle of operation of guide wheels 1208; when track carrier 112 is placed in track 104, guide wheel 1208 is located in guide wheel channel 510 with just enough clearance to move in rotatingly, free manner. Because guide wheels 1208 are located at or near the extreme ends of track carrier 112, guide wheels 1208 substantially prevent any side-to-side movement of track carrier 112 as it moves within track carrier 112.

In furtherance of the desired substantially smooth, non-rotational motion of track carrier 112 according to an embodiment, track carrier wheel assemblies 1202 a,b sit within track carrier wheel guides 1502 a,b, further substantially preventing any side-to-side motion of track carrier 112, due to the frictional engagement of the grooves of track carrier wheel guides 1502. As those of skill in the art can appreciate, side-to-side motion of track carrier 112 will lead to situations in which binding can occur and/or excessive noise. That is, if track carrier 112 were allowed to wander within carrier channel 508, then it could bind, and/or create excessive noise as it moved from side-to-side. According to a further embodiment, however, and as discussed above, tracks 104 do not contain track carrier wheel guides 1502, and instead are substantially smooth and planar on the same surface. Track carrier 112, using track carrier wheel assemblies 1202 manufactured in accordance with the discussion herein, do not suffer from excessive side-to-side motion, and binding and excessive noise is substantially prevented. Further, due to the loads that can be borne by track carriers 112 use of track carrier wheel assemblies 1202 as described herein exhibit substantial strength and can move the loads (heavy drapes) without binding, excessive noise, and premature failure.

In furtherance of the desired substantially noise-free and binding-free operation of track carrier 112, track carrier wheel assembly 1202, which is made of track wheel rim 1203 and track wheel urethane tire (tire) 1204, provides substantially smooth noise-free operation through carrier channel 508. As with truck tire 408, track wheel tire 1204 can be fashioned in the form of an O-ring, and manufactured according to the processes described above. Track wheel tire 1204 can be made of urethane, which is softer than the polystyrene plastic that is typically used in the manufacture of many of the other components of drapery system 100, as those of skill in the art can appreciate. Track wheel tire 1204 according to an embodiment provides not only a softer, cushioned interface between track carrier wheel guide 1502 of carrier channel 508 and track carrier 112, but it also provides a greater frictional engagement with track carrier wheel guide 1502. However, as those of skill in the art can appreciate, the frictional engagement typically does not come into play when track carrier wheel assembly 1202 rotates, but does come into play if track carrier wheel assembly 1202 attempts to move in a side-to-side (lateral) motion (see arrows A and B in FIG. 15). Thus, use of the track wheel urethane cover as track wheel tire 1204 over track wheel rim 1203 substantially prevents side-to-side motion, which substantially eliminates binding and excessive noise according to an embodiment. Furthermore, it should be apparent to those of skill in that art that while a specific material has been discussed in regard to the aspect of the embodiments of track wheel tire 1204, other materials can also be used that are different than urethane that provide substantially similar functionality in terms of frictional engagement and cushioning affect. Thus, the aspects of the embodiments are not meant to be, nor should they be taken to be limited to urethane as the only material of which track wheel tire 1204 can be made of.

In furtherance of the desired effect of non-binding of the components of drapery system 100, including those that operate within track 104, each of wheel assemblies 1201 are rotatable independently of each other. That is, if, for example, track carrier wheel assembly 1202 b binds, for whatever reason, as shown in FIG. 17 (see point A in FIG. 17), track carrier wheel assembly 1202 a of track carrier 112 need not bind as well and will continue to rotate freely about its axis of rotation. While having independently rotatable track carrier wheel assemblies 1202 cannot prevent binding, should it occur, it lessens the impact by at least half by allowing the non-binded wheel to continue to rotate. As those of skill in the art can appreciate, binding can occur as shown in FIG. 17 when an owner/operator of drapery system 100 pulls drapes 106 to one side or the other, or if some impediment gets in the way of drapes 106.

FIGS. 16A and 16B illustrate a portion of a simplified side and top view of track carrier 112 of FIGS. 12-14 with guide wheel assembly 1600 according to a further embodiment. In the embodiment shown in FIGS. 16A and 16B, guide wheel 1208 has now been replaced by guide wheel assembly 1600, which comprises guide wheel 1208′ and guide wheel urethane tire (guide wheel tire) 1602. As with truck tire 408, guide wheel tire 1602 can be fashioned in the form of an O-ring, and manufactured according to the processes described above. In this aspect of the embodiments, guide wheel rim 1601 is slight different than guide wheel 1208 in that the former will have a smaller diameter than that of the latter in order to allow for the relatively thin layer of guide wheel tire 1602 that covers guide wheel rim 1601. That is, in order to allow guide wheel assembly 1600 to take the place of guide wheel 1208, guide wheel rim 1601 generally will have a smaller diameter so that when guide wheel tire 1602 is put over guide wheel rim 1601 it will fit within guide wheel channel 510 (presuming, however, that a substantially similar or the same track 104 is being used for both aspects of the embodiments).

According to an aspect of the embodiments, as with track carrier wheel assembly 1202 and its respective track wheel urethane tire 1204, guide wheel tire 1602 can also be made of urethane, or some other similar material that exhibits similar or substantially similar characteristics, so that a substantially frictionless rolling and cushioned engagement occurs between guide wheel assembly 1600 and track 104 within guide wheel channel 510, but which also provides frictional engagement in any unwanted up-down motions of track carrier 112 to limit such up and down motions (see FIG. 15, and arrows C and D). That is, as track carrier 112 moves within carrier channel 508, and either or both of guide wheel 1208 or guide wheel assembly 1600 moves within guide wheel channel 510, guide wheel 1208 or guide wheel assembly 1600 prevent any unwanted motion other than the motion in the direction of travel which is in the direction of track 104 (e.g., perpendicular to the plane of the drawing sheet of FIG. 15), even if track 104 is curved.

Furthermore, it should be apparent to those of skill in that art that while a specific material has been discussed in regard to the aspect of the embodiments of guide wheel tire 1602, other materials can also be used that are different than urethane that provide substantially similar functionality in terms of frictional engagement, and cushioning affect. Thus, the aspects of the embodiments are not meant to be, nor should they be taken to be limited to urethane as the only material of which guide wheel tire 1602 is comprised of.

The following is a list of the acronyms used in the specification in alphabetical order.

TB Timing Belt TBG Timing Belt Gear

The disclosed embodiments provide a system and a method of operation for a drapery system that can include motorized components for moving drape 106 along track 104. Drapery system 100 according to different aspects of the embodiments include: (a) rounded striations within track 104 to reduce friction and extend the life of timing belt 202; (b) height adjustment mechanisms to ensure the evenness and proper fitting of drapes 106; (c) alignment pins and respective channels within track 104 to facilitate better alignment of tracks 104 and thus smooth operation of track carrier 112, thereby reducing noise and ensuring substantially error-free operation; (d) a mechanism for securing track(s) 104 to supporting structure in a hardier and more secure manner; and (e) track carrier 112 that includes track carrier wheel assembly 1202 that comprises track wheel urethane tire 1204 for substantially noise- and error-free operation of drapery system 100.

It should be understood that this description is not intended to limit the embodiments. On the contrary, the embodiments are intended to cover alternatives, modifications, and equivalents, which are included in the spirit and scope of the embodiments as defined by the appended claims. Further, in the detailed description of the embodiments, numerous specific details are set forth to provide a comprehensive understanding of the claimed embodiments. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.

Although the features and elements of aspects of the embodiments are described being in particular combinations, each feature or element can be used alone, without the other features and elements of the embodiments, or in various combinations with or without other features and elements disclosed herein.

This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.

The above-described embodiments are intended to be illustrative in all respects, rather than restrictive, of the embodiments. Thus the embodiments are capable of many variations in detailed implementation that can be derived from the description contained herein by a person skilled in the art. No element, act, or instruction used in the description of the present application should be construed as critical or essential to the embodiments unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items.

All United States patents and applications, foreign patents, and publications discussed above are hereby incorporated herein by reference in their entireties. 

1. A drapery track system, comprising: one or more drapes; a motor configured to be operable to spin a shaft in both a clockwise direction and a counterclockwise direction, wherein said clockwise spin direction of said shaft creates a first movement of said one or more drapes in a first direction, and wherein said counterclockwise spin direction of said shaft creates a second movement of said one or more drapes in a second direction opposite to said first direction; a track system that includes at least one track length secured to a fixed surface via a track securing mechanism, and a gearing assembly configured to interface with said motor and to translate said clockwise spin direction and counterclockwise spin direction to said first and second movements, respectively, of said one or more drapes, and wherein said at least one track length includes a carrier channel and a guide wheel channel, and wherein said gearing assembly includes a timing belt configured to be rotated by said motor, and wherein said track system further includes at least one track carrier configured to be attached to said timing belt such that said one or more drapes can be moved by said at least one track carrier that is moved by said timing belt that is moved by said motor, and wherein said track carrier includes at least a first and second independently mounted track carrier wheel assembly, each of which are configured to rotate independently of each other within said carrier channel such that if one of said independently mounted wheel assembly binds the other independently mounted wheel assembly can freely rotate, and wherein said track carrier further includes a first and second guide wheel assembly, said first and second guide wheel assemblies each comprising respective guide wheels configured to freely rotate about a respective axis of rotation, wherein said first guide wheel assembly is located at a first extreme end of said track carrier and near a first track carrier wheel assembly that is located near the first extreme end of said track carrier, but wherein said first guide wheel assembly is closer to the first extreme end then the first track carrier wheel assembly, and further wherein said second guide wheel assembly is located at a second, opposite extreme end of said track carrier than the first extreme end of said track carrier and near a second track carrier wheel assembly that is located near the second extreme end of said track carrier, but wherein said second guide wheel assembly is closer to the second extreme end then the second track carrier wheel assembly, and wherein said first and second guide wheel assemblies are configured to substantially prevent rotation and binding of said track carrier within said carrier channel; and a drape truck assembly configured to be removably secured to said one or more drapes, and wherein said drape truck assembly includes at least two independently rotating truck wheels configured to freely rotate within said carrier channel of said track length such that said one or more drapes can be moved by said motor.
 2. (canceled)
 3. The drapery track system according to claim 1, wherein each of said guide wheel assemblies comprises: a guide wheel rim configured to rotate about a first axis perpendicular to a direction of travel of said track carrier; and a first outer tire portion located over said guide wheel rim, said first outer tire portion made of a substantially softer, higher frictional material than a material that said guide wheel rim is made of, such that said guide wheel assembly is configured to rotate substantially freely about the first axis, but is frictionally resistant to movement in any direction other than the direction of rotation.
 4. The drapery track system according to claim 3, wherein said substantially softer, higher frictional material comprises urethane.
 5. The drapery track system according to claim 1, wherein each of said plurality of independently mounted track carrier wheel assemblies comprises: a track wheel rim that is independently rotatable of said other truck wheel rims attached to a track carrier body portion of said track carrier, and wherein said track wheel rim is configured to rotate about a second axis perpendicular to a direction of travel of said track carrier; and a track wheel tire located over said track wheel rim, said track wheel tire made of a substantially softer, higher frictional material than a material that said track wheel rim is made of, such that each of said independent mounted truck carrier wheel assemblies are configured to rotate substantially freely about said second axis, but is frictionally resistant to movement in any direction other than the direction of rotation.
 6. The drapery track system according to claim 5, wherein said substantially softer, higher frictional material comprises urethane.
 7. The drapery track system according to claim 1, wherein each of said plurality of independently mounted track carrier wheel assemblies comprises: a track wheel that is independently rotatable of other track wheels attached to a track carrier body portion of said track carrier, and wherein each of said track wheels are configured to rotate about an axis perpendicular to a direction of travel of said track carrier.
 8. The drapery track system according to claim 1, wherein said carrier channel comprises: a plurality of track carrier wheel guides located at a bottom of said carrier channel, and wherein each of said plurality of track carrier wheel guides are configured to retain a respective one of said plurality of track carrier wheel assemblies when rotating, such that lateral movement of said track carrier is substantially prevented.
 9. The drapery track system according to claim 1, wherein said track securing mechanism comprises: a substantially centrally located track retention channel, located within an upper interior surface of said track carrier channel, wherein said substantially centrally located track retention channel runs a length of said track length; a reinforced area of track length material located about said substantially centrally located track retention channel configured to strengthen said track length in a location of said substantially centrally located track retention channel; a first plurality of track mounting holes located along a scribe line that is substantially centrally located within said substantially centrally located track retention channel; and a second plurality of track securing apparatuses, each of which is configured to be placed within a respective one of said first plurality of track mounting holes and secured to said fixed surface.
 10. The drapery track system according to claim 1, further comprising: at least one other track length, wherein each track length includes two or more dowel pin holes correspondingly located on both ends of said track length such that a first dowel pin hole of a first track length at a first end of said first track length is in substantial alignment with a second dowel pin hole located on a second track length at a second end of said second track length; and a plurality of dowel pins, each of said plurality of dowels including one or more fins, configured to be inserted into first into either of first or second dowel pin hole of a first track length, and then to be inserted into either of corresponding said second or first dowel pin holes of a second track length, thereby joining two or more track lengths together in substantial alignment.
 11. The drapery track system according to claim 10, wherein said dowel pins further comprise: a plurality of fins, located on both ends of said dowel pins.
 12. The drapery track system according to claim 1, further comprising: a timing belt configured to be moved by said motor to move said drapes, and wherein said at least one track length further includes a first and second timing belt channel, wherein each of said timing belt channels are formed by a timing belt channel inner wall and a timing belt channel outer wall, and wherein, each of said timing belt channel outer walls has an exterior surface that forms an outer layer surface of said at least one track length, and an inner surface, and wherein each of said inner surface of said timing belt channel outer walls includes a plurality of substantially rounded striations of a first predetermined radius, said striations configured to provide a substantially frictionless surface with respect to said timing belt.
 13. The drapery system according to claim 1, wherein said drape truck assembly further comprises: a truck wheel carriage configured to mate with said least two independently rotating truck wheels; a truck height adjustment piece received by a bottom, lowest hanging portion of said truck wheel carriage, and configured to removably secure said one or more drapes to said truck wheel carriage, and further wherein said truck height adjustment piece is configured to be substantially continuously adjustable in height with respect said bottom, lower hanging portion of said truck wheel carriage, from between a lowermost position to an uppermost position, such that a height of said one or more drapes with respect to one or more horizontal surfaces can be adjusted.
 14. The drapery system according to claim 13, wherein said truck height adjustment piece comprises: a bolt with a threaded portion configured to be received in a bolt-receiving threaded portion located on said bottom, lower hanging portion of said truck wheel carriage, such that upon turning said bolt in a clockwise or counter-clockwise direction, said drape can be raised or lowered, or visa-versa.
 15. The drapery system according to claim 13, wherein each of said at least two independently rotating truck wheels comprises: a truck rim portion that is independently rotatable of said other truck rim portions attached to said truck wheel carriage, and wherein said truck rim portion is configured to rotate about a third axis perpendicular to a direction of travel of said truck assembly; and a truck tire portion located over said truck rim portion, said truck tire portion made of a substantially softer, higher frictional material than a material that said truck rim portion is made of, such that each of said independently rotatable truck wheels are configured to rotate substantially freely about said third axis, but are frictionally resistant to movement in any direction other than the direction of rotation.
 16. The drapery track system according to claim 15, wherein said substantially softer, higher frictional material comprises urethane.
 17. A track carrier for use in a drapery track system, comprising: a first and second track carrier body part, configured to be joined together to form said track carrier, wherein each of said first and second track carrier body parts include first and second “L” shaped guide wheel mounting portions respectively, and further wherein said first and second “L” shaped guide wheel mounting portions form respective elongated portions extending away from each other and a middle portion formed by said joining of said first second track carrier body parts; a plurality of track carrier wheel assemblies each of which are configured to rotate about respective axes of rotation that comprise a first set of axes of rotation, and wherein each axis of rotation of said first set of axes of rotation are substantially perpendicular to first and second directions of travel of said tracker carrier; a plurality of guide wheel assemblies each of which are configured to rotate about respective axes of rotation that comprise a second set of axes of rotation, and wherein each axis of rotation of said second set of axes of rotation are substantially perpendicular to each axis of rotation of said first set of axes of rotation, and further wherein each axis of rotation of said second set of axes of rotation are substantially perpendicular to said first and second directions of travel of said track carrier, and wherein said plurality of guide wheel assemblies are located on respective first and second “L” shaped guide wheel mounting portions; and a joining plate configured to be placed between said first and second track carrier body parts and to facilitate joining of said first and second track carrier body parts together.
 18. The track carrier according to claim 17, further comprising: a plurality of timing belt clip attachment receptacles, and wherein said drapery track system includes one or more tracks, wherein each of said tracks includes a carrier channel (508) configured to receive said plurality of track carrier wheel assemblies of said track carrier, and a timing belt configured to move said track carrier in both said first and second directions, said timing belt including a plurality of timing belt clips configured to releasably attach to said respective ones of said plurality of timing belt clip attachment receptacles, and further wherein each of said tracks further includes a guide wheel channel (510) configured to receive said plurality of guide wheels of said track carrier, and wherein each of said plurality of track carrier wheel assemblies are configured to rotate within said carrier channels of said one or more tracks and wherein each of said plurality of track carrier guide wheel assemblies are configured to rotate within said guide wheel channels of said one or more tracks.
 19. The track carrier according to claim 17, wherein said track carrier wheel assembly comprises: a plurality of track wheel rims made of a first material, and wherein each of which is independently rotatable of other truck wheel rims attached to a track carrier body portion of said track carrier, and wherein each said track wheel rim is configured to rotate about an axis perpendicular to a direction of travel of said track carrier; and a track wheel tire made of a second material, and which is configured to be located over said track wheel rim such that said track wheel tire contacts portions of said carrier channel while each of said plurality of track wheel assemblies rotates.
 20. The track carrier according to claim 19, wherein said second material is softer than said first material and exhibits greater frictional contact with said carrier channel in any direction not in said first and second directions of travel when rotating.
 21. The track carrier according to claim 20, wherein said second material comprises urethane.
 22. The track carrier according to claim 17, wherein said track carrier wheel assembly comprises: a track wheel that is independently rotatable of other track wheels attached to a track carrier body portion of said track carrier, and wherein each of said track wheels are configured to rotate about an axis perpendicular to a direction of travel of said track carrier.
 23. The track carrier according to claim 17, wherein each of said a plurality of guide wheel assemblies comprises: a guide wheel rim made of a third material; and a guide wheel tire made of a fourth material, and which is configured to be located over said guide wheel rim such that said guide wheel tire contacts said guide wheel channels while each of said plurality of guide wheel assemblies rotates.
 24. The track carrier according to claim 23, wherein said fourth material comprises urethane.
 25. The track carrier according to claim 17, wherein said plurality of guide wheel assemblies comprise: a first guide wheel assembly located at a first end of a first guide wheel portion of said track carrier; and a second guide wheel assembly located at a first end of a second guide wheel portion of said track carrier opposite to that of said first end guide wheel portion, wherein in operation within said guide wheel channel, said pair of guide wheel assemblies are configured to substantially prevent rotation of said track carrier about any axis substantially perpendicular to said line formed by said first and second directions of travel, and further wherein said first guide wheel assembly is located at a first extreme end of said track carrier and near a first track carrier wheel assembly that is located near the first extreme end of said track carrier, but wherein said first guide wheel assembly is closer to the first extreme end then the first track carrier wheel assembly, and further wherein said second guide wheel assembly is located at a second, opposite extreme end of said track carrier than the first extreme end of said track carrier and near a second track carrier wheel assembly that is located near the second extreme end of said track carrier, but wherein said second guide wheel assembly is closer to the second extreme end then the second track carrier wheel assembly.
 26. The track carrier according to claim 17, wherein each of said plurality track carrier wheel assemblies is configured to rotate independently of each other.
 27. The track carrier according to claim 17, wherein each of said plurality guide wheel assemblies is configured to rotate independently of each other.
 28. The track carrier according to claim 17, wherein each of said axes of said first set of axes of rotation reside within a first plane, and wherein each of said axes of said second set of axes of rotation reside within a second plane, and further wherein said first plane and said second plane are perpendicular to each other and to a third plane that encompasses said first and second directions of travel.
 29. A track for use in a drapery track system comprising: a pair of timing belt channels configured to contain a timing belt therein, each of said pair of timing belt channels formed by a timing belt channel inner wall and a timing belt channel outer wall, wherein said timing belt channels are substantially parallel to each other, and wherein said timing belt outer walls form an outer portion of said track; a carrier channel located between said timing belt inner walls, formed in part by said timing belt channel inner walls; a substantially planar bottom for both of said pair of timing belt channels, and wherein an opening is formed in said substantially planar bottom wall in said carrier channel to form a guide wheel channel; a track mounting mechanism configured to secure said track to a fixed surface, wherein said track mounting mechanism comprises a substantially centrally located track retention channel, located within an upper interior surface of said track carrier channel, wherein said substantially centrally located track retention channel runs a length of said track; and a plurality of substantially rounded striations located on each of said inner wall portions of both of said timing belt channel outer walls, wherein said striations have a first predetermined radius, and said striations are configured to provide a substantially frictionless surface with respect to said timing belt.
 30. The track according to claim 29, further comprising: at least a first and second track piece; at least four dowel pin holes, two of which are located at a first end of said first track piece, and two of which are located at a second end of said second track piece, such that when a second end of said second track piece is located adjacent to said first end of said first track piece, the four dowel pin holes are in substantial alignment with each other; and a plurality of dowel pins, each of said plurality of dowels including one or more fins, wherein said dowel pins can be inserted into any of said dowel pin holes on said first track piece or said second track piece, and mate with corresponding dowel pin holes on said second track piece or said first track piece, thereby joining two or more track pieces in substantial alignment.
 31. The track according to claim 30, wherein said dowel pins further comprise: the one or more fins on said dowel pins located at a first end of said dowel pin.
 32. The track according to claim 30, wherein said dowel pins further comprise: a plurality of fins located on both sides of said dowel pin.
 33. The track according to claim 29, wherein said track mounting mechanism further comprises: a reinforced area of track material located about said substantially centrally located track retention channel configured to strengthen said track in a location of said substantially centrally located track retention channel; a scribe line located substantially centrally within said track retention channel; a plurality of track mounting holes located along said scribe line; and a plurality of track securing apparatuses, a respective one of each to be placed within a respective one of said plurality of track mounting holes and secured to a fixed surface upon which said track is to be mounted.
 34. The drapery system according to claim 13, wherein the amount of adjustment is substantially similar to the length of the adjustment on said truck height adjustment piece, such that a height of said one or more drapes with respect to one or more horizontal surfaces can be adjusted.
 35. The draper system according to claim 13, wherein said truck height adjustment piece is configured to be substantially continuously adjustable in height with respect said bottom, lower hanging portion of said truck wheel carriage, from between a lowermost position to an uppermost position, such that a height of said one or more drapes with respect to one or more horizontal surfaces can be adjusted. 